Induction heating equipment is a type of areas that many people need to know more about. We have to know when and easy methods to apply this technology, if it is the fitting one for the job and easy methods to purchase it if we need to do so. Let’s study more.
Power Supply
Power, expressed in kilowatts (kW), refers back to the induction power-supply size. A power supply must be sized to heat a given mass or given surface space to a particular temperature within a specified time. A basic rule of thumb is that the surface area (uncovered to the coil) used to determine the ability level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the facility density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for many induction applications.
More power shouldn’t be essentially better. Matching the facility and frequency is the key. While more power lets you heat faster, it can also soften the surface or produce a deeper pattern (there is also more hazard of through hardening), and it is harder to manage grain growth.
Frequency
High frequency within the form of alternating present is passed by the coil to create a magnetic area producing eddy currents. These are generated within the metal under the surface, and the resistance to this current flow is the principal source for heating of the metal.
The next guideline for «relative» depth of penetration (depth of hardening or case depth) as a function of frequency is perhaps useful. This information is application-specific and dependent on each power density and heat time however is considered typical of what is discovered in the business:
@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch
@ 100 kHz the case depth developed is (approximately): 0.050-0.080 inch
@ 30 kHz the case depth developed is (approximately): 0.080-0.a hundred and twenty inch
@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch
The depth of present penetration (hardened depth) is a function of part diameter and the resistivity of the material. There’s an optimum depth of current penetration range, which is what each producer strives to provide.
Higher frequency has a definite advantage when you will have marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy close to the surface of the part, avoiding lengthy heating occasions or requirements for higher power density (more expensive in terms of $/kW).
Tuning
Tuning (energy-supply load matching) is an important consideration to achieve the desired case-depth profiles and for general power-system efficiency. This is finished by adjusting the faucet of a variable-ratio transformer or by adding/subtracting a portion of a capacitor to achieve the desired frequency and a balanced load match between amperes, volts and kW. These are typically considered on a meter panel on the facility supply.
The goal is to have a system that requires a minimal quantity of tuning, which becomes more important as energy levels approach the maximum nameplate rating of the power supply. For consistency of heating, the ability provide ought to be tuned so that it is not running to its limit.
Computer-controlled and recipe-chosen computerized capacitor contactors can be utilized to load match when many alternative workpiece sizes are heat handled on the identical piece of equipment. Many power-supply producers design a tuning window that allows you to make some changes to the part dimension being run. When only one part is dedicated to a system, no tuning is required after initial setup and testing.
Coils
All workpieces have their own function, shape and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They’re designed and constructed specifically to fulfill the metallurgical requirements and production rates of the workpiece. Coils require periodic upkeep (repair) and have to be suitable for the applications whether it be scanning, static heating or single-shot heating.
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